Module

1
Introduction to
Programmable
Controllers

PLC Video Training Guide and Workbook

1-1

INTRODUCTION
This first training module introduces you to Programmable Controllers, its general control
concept and the areas of applications in industry in which they are being applied. General
operation, including its scanning method, is also covered in an introductory manner to
prepare you for future modules (Module 4).
Additionally, this module immediately gets you into the relationship of electromechanical
relay control systems and programmable controller based systems. Input and output
addressing of field devices is also covered as it relates to programmable controllers and its
interaction with the real world.

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INSTRUCTIONAL OBJECTIVES
After reviewing this module, you should be able to:
Understand why and how programmable controllers are being used.
Describe the benefits of using this technology in industrial automation applications.
Understand its principle of operation (scanning) and the way programmable
controllers address field input and output devices.
Describe the relationship between relay systems and programmable controller
systems using ladder diagram symbols to control field output devices.

1-3

MODULE REVIEW
Programmable controllers, which are formally called Programmable Logic
Controllers or PLCs for short, are defined as special members of the computer family,
capable of storing instructions to implement control functions such as:
Sequencing
Counting
Timing
Arithmetic, and
Data manipulation
to control industrial machines and processes. PLCs use familiar symbolic instructions to
implement all these functions and more.
Programmable Controllers, in a few words, measure signals from the process or machine
via input field devices and then, through the control program, control output field devices
which are connected to the process or machine being controlled.

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Video Module 1

Initial development goals for PLCs include:

Elimination of the high cost associated with changes in wiring in
electromechanical relay control systems generally experienced
during installations.
Reduction of downtime caused by mechanical failures and system
changes.
Additional benefits included:
Improvements in system efficiency
Enhancement of product quality
The ability to provide access to process information
Easy installation
Use of less space and energy
Being reusable for other applications.
Some of the most important characteristics of programmable controllers include:
Solid state components
Flexible architecture, or configuration, of input and output interfaces
Built to sustain harsh industrial environments.
The basic operation of the PLC is to:
Read the input status of field input devices
Execute the control program stored in the PLC
Update or control the field output devices according to the
control logic
The operation of reading the inputs, executing the program and updating the outputs
is known as the SCAN.
Programmable controllers come in many sizes to accommodate different
applications according to the number of field devices to be connected and by the
functions to be performed to provide control.
When PLCs were first developed, one of the primary intentions was to have its
programming language (ladder diagrams) similar to the one used in relay systems
which PLCs were to replace. This allowed for easier use of PLCs in relay
replacement applications to personnel already familiar with ladder diagrams.
The PLCs ladder diagram language references or addresses input and output (I/O)
field devices connected to the controller via I/O interfaces.

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PLC Video Training Guide and Workbook

1-4

VIDEO GUIDE
Notes
Definition And Background

PROCESS
OR
MACHINE

MEASURE

CONTROL

PROGRAMMABLE
CONTROLLER

FIELD
INPUTS

FIELD
OUTPUTS

PLC Application Concept

Principles of Operation

I
N
P
U
T
S

Central
Processing
Unit

O
U
T
P
U
T
S

PLC Basic Concepts

1-4

Video Module 1

1
Notes

PLC SYSTEM
FIELD
INPUTS

SENSE

DECIDE

CONTROL

INPUT
MODULES

CPU

OUTPUT
MODULES

FIELD
OUTPUTS

Fuctioninal Operation

INPUT
INTERFACES

OUTPUT
INTERFACES

CPU

PROGRAMMING
DEVICE

COMPLEXITY AND COST

5
C
4
B
3
A
2
1
32

64

128 512 1024 2048 4096

8192

I/O COUNT

PLC Product Range

1-5

PLC Video Training Guide and Workbook

1
Notes
Relay Logic and The PLC

L1
PB5
Emergency
Stop

L2

PB7
Start

PB6
Stop

M2

OL2

F
M2
PB9
Start

PB8
Stop

All
OL's3

M3
R

M3

L1

L2

L1
5

PB5

L2

33

M1 OL2
33

33

PB6
6
PB7

10

11

7
PB8

34
34

All
M2 OL's3
R

34
10

PB9
11

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Video Module 1

1
Notes
Ladder Diagram and The PLC
(Addressing)

L2

L1
LS1

PB1

PL

LS2

Inputs
L1

Outputs

PLC
L2

L1

PB1

PB1

LS1

LS2

LS1

PL

L2
PL

LS2

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PLC Video Training Guide and Workbook

1-5

REVIEW QUESTIONS

1-1

True/False. A programmable controller can be considered as a special member of the

computer family.

12

Sketch the conceptual operation of a PLC that includes its measuring and control of a
process or machine.

13

Which of the following was not one of the primary goals associated with the development of PLCs.
aTo eliminate hardwired relay systems
bTo reduce machine downtime
cTo ease troubleshooting
dTo replace mainframe computers
eTo ease system changes (e.g., programming)

14

True/False. PLCs use more energy than electromechanical systems.

1-5

Programmable controllers work hand-in-hand with _____ and _____ in industrial automation facilities.
aDiagnostic indicators
bRobots
cManagement Information Systems
dHardware timers

1-6

True/False. Programmable controllers can be used in virtually all sorts of industrial

applications.

1-7

The CPU is composed of _____, _____ and _____.

aI/O Modules
bProcessor
cProgramming Device
dMemory
ePower Supply

1-8

Name three typical output field devices that are controlled by a PLC via output
interfaces.

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Video Module 1

1
1-9

True/False. The operation of a PLC in basic terms is reading the inputs, executing the
control program and updating the outputs.

1-10

The purpose of the I/O interfaces is to _____ the various signals received from or sent
to external field devices.
aSense and control
bProvide isolation to
cCondition
dAll of the above

1-11

Match the following:

___
___
___

Handheld unit
Self-contained video display
Used to program PLCs but
are not dedicated units

aCRT
bMini-Programmer
cPersonal Computers

1-12

True/False In the early days, PLCs were encountered in two major types: Small
PLCs and large PLCs.

1-13

True/False. Very large PLCs are powerful controllers capable of utilizing up to 8192
I/O field devices.

1-14

True/False. There is a lot of similarity in the way electrical controlled sequences are
represented in PLCs.

1-15

True/False. In Figure1, the pilot light will be on if PB1 and LS1 are on, or if LS2 and
LS1 are both on.

L2

L1
PB1

LS1

LS2

Figure1

1-9

PL

PLC Video Training Guide and Workbook

1-16

In Figure 2, the PL output coil in the ladder diagram will turn ON if PB1 and LS1 are ON
or if _____.
aPB1 is disconnected
bLS2 and LS1 are ON
cLS1 closes
dAll of the above

Inputs
L1

Outputs

PLC
L2

L1

PB1

PB1

LS1

LS2

LS1

PL

L2
PL

LS2

Figure 2
1-17

When it is said that field devices are addressed by their respective input and output interface
module, it refers to:
aRemote I/O locations and wiring
bThe PLCs ability to read inputs, execute the instructions and update theoutputs
cEach programmed element (contact and coil) is represented by the connection location
of each field device in a PLC module
dThe actual wiring of the field devices in the control panel

1-18

True/False. In Figure 2, the actual pilot light will be turned ON right after the processor
updates the outputs.

1-19

True/False. In Figure 2, if PB1 was ON and then released and LS1 is closed, the light will
be on.

1-20

True/False. In Figure 2, we can say that the programmed instructions are wired so to
speak, inside the PLC.

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Video Module 1

1-6

HOW DID YOU DO?

1-1

True.

1-2

Conceptual design sketch.

PROCESS
OR
MACHINE

MEASURE

FIELD
INPUTS

CONTROL

PROGRAMMABLE
CONTROLLER

FIELD
OUTPUTS

1-3

d.- To replace mainframe computers.

1-4

False. PLCs use less energy and space than electromechanical relay systems.

1-5

b.-Robots
c.-Management Information Systems (MIS)

1-6

True.

1-7

b.-Processor
d.-Memory
e.-Power Supply.

1-8

Solenoids, motor starters, pilot lights, etc.

1-9

True.

1-10

d.- All of the above.

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___
b
___
a
___
c
___
___
___

Handheld unit
Self-contained video display
Used to program PLCs but
are
not dedicated
units
Handheld
unit
Self-contained video display
Used to program PLCs but
are not dedicated units

aCRT
bMini-Programmer
cPersonal Computers
aCRT
bMini-Programmer
cPersonal Computers

1-11

PLC Video Training Guide and Workbook

1
1-12

True.

1-13

True.

1-14

True.

1-15

True.

1-16

b.- LS2 and LS1 are ON

1-17

c.-Each programmed element (contact and coil) is represented by the connection

location of each field device in a PLC module.

1-18

True.

1-19

False. There must be power continuity for the light to be on. PB1 breaks the power
continuity.

1-20

True.

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